Re: The Hillbilly Deluxe dually build
 

I feel you on the lack of progress grumbles...

Re: The Hillbilly Deluxe dually build
 

You're a better man than I- I'm a giant cold sissy. Which reminds me- I need to go pick up a bigger Mr. Heater for the garage.

Re: The Hillbilly Deluxe dually build
 

I had to go out last year and bought a 215,000 btu heater. Been finding it hard to leave the shop here lately. They are noisey but put out alot of heat.

Re: The Hillbilly Deluxe dually build
 

Half of my shop is very nice to work in. It's all insulated and drywalled with a big old Dearborn heater. I have all of my workbenches and tools in that part. So, on the taillights for instance, I crimped and soldered the wires in short sleeve comfort at my workbench, then ducked outside into the bad weather to bolt them on to the truck and connect the wires. That's why I'm a motorcycle restoration guy mainly. I can work in absolute comfort 12 months per year in that part of the shop. Motorcycle lift table in the center, tools at hand.

The cold side of my shop is where my powdercoat booth, blasting cabinets, compressor and stuff are. I avoid that section from about November through March. I have one of those torpedo heaters for the cold side of the shop, but it's noisy and uses more diesel than I care to feed it so I try to avoid it all together.

Re: The Hillbilly Deluxe dually build
 

Awesome job so far. This is want I want to do if I find one I can live with. Definitely a working mans build for a working mans working truck. Very cool.

Re: The Hillbilly Deluxe dually build
 

Still waiting on parts fellas.

This bad weather shut down UPS and Postal Service deliveries. Should be seeing some of my stuff tomorrow. Then I'll get the fuel filler situation figured out.

Out of boredom I've been picking up some various tools on eBay. I need to put the iPad down and get back out into the shop to save some money. I'm a tool geek and have been buying a few specific MAC tools I wanted and some Martin body hammers. Nothing new of course. Only "seasoned vintage" stuff.

Patience...

Re: The Hillbilly Deluxe dually build
 

Kevin - tools are like these old trucks, they too can become an addiction...

Re: The Hillbilly Deluxe dually build
 

Karl,

I can't really justify my whims on particular tools. I've had a very nice set of SnapOn wrenches for 22 years now. I fixed a ton of cars and made a lot of money with them. But, a few years ago, I came up with a MAC 9/16 wrench somewhere. I don't even remember where. Found it in an old truck or something. Every since then, when I need a 9/16 wrench, I skip right over the rack of matching SnapOns and grap that lone MAC wrench. So, I've started to accumulate an entire set. They're just eBay singles that I pick up for 5 or 10 dollars every so often. They've always got some various blemish on them somewhere. I sure like them a ton better than the 500 dollar set of SnapOns.

http://i276.photobucket.com/albums/k...9029fbf34e.jpg

Today, I went to the Post Office in person to find my missing stuff. It's very icy here and the mail lady has only been delivering stuff that will fit in the mailbox at the end of my driveway. She doesn't venture up icy driveways to deliver bigger packages. I don't blame her, its treacherous here and I wouldn't spend my entire day white knuckling up icy driveways either. So, there's literally large bins of packages accumulating at the Post Office. I got a nice lady down there that likes me who was nice enough to spend 20 minutes digging out my boxes.

Ford gas filler bezel from eBay. I got three of them in one auction that are various configurations.


http://i276.photobucket.com/albums/k...4b7655b525.jpg

Make template for the hole I need to cut...

http://i276.photobucket.com/albums/k...f011b708b6.jpg

Used my electric torch to slice the old filler out and make way for the new. Yes I went all safety minded and covered over the filler hose on the tank so the plasma sparks didn't do something that caused me to make the local news.


http://i276.photobucket.com/albums/k...c1137ca3b3.jpg

Test fit. Looks good so far. I need to make an addition below the bed side to finish out the opening. I'm working on that now.

http://i276.photobucket.com/albums/k...c58d15b994.jpg

Notice there's still ice on everything and I'm wearing gloves. I sure wish this crap would thaw off. There's a reason I live in Texas and not someplace "up north" where this is normal weather.

Re: The Hillbilly Deluxe dually build
 

I took some 1/8 inch plate and cut an extension to complete the opening then welded it to the bed.

http://i276.photobucket.com/albums/k...f44e9ba9b6.jpg

Masked and sanded...

http://i276.photobucket.com/albums/k...f2839d312d.jpg

Then got out the heat gun and my finest can of Rustoleum rattle can. Using the heat gun, I was able to set and cure the paint enough that I think it will be okay with the low temperature. They way the truck is sitting the sun will be shining on it all day.

http://i276.photobucket.com/albums/k...c323c2e38a.jpg

I'll let it sit until Friday before I mount the bezel and filler neck and drill the holes to secure it.

I have a large UPS delivery of parts that I need to finish this phase of the project that is stuck in UPS purgatory in Mesquite Texas. They shut down all operations for four days so there is apparently a huge backlog of stuff waiting to be delivered. Maybe tomorrow.

Now, I need help here. This is the hard line for the fuel filler vent tube. Its 5/8 of an inch O.D. Where can I buy a stick about 3 feet long of replacement hard line ? Is there some conduit or something that is a similar size ? I want to run a hard line parallel to the main filler line with little sections of hose connecting it to the filler neck and gas tank.

http://i276.photobucket.com/albums/k...60104df392.jpg

Anyone ?

Re: The Hillbilly Deluxe dually build
 

Do you have a hydraulic hose store like a Parker Store close to you? All the local shops here carry 5/8" steel hydraulic line in stock and will cut and bend to your drawing if needed. I beleive Stuart Hose & Pipe has a store in Ft. Worth and so does Midwest Hose & Specialty. They should have what you need.

Re: The Hillbilly Deluxe dually build
 

That's a good lead. I use a little hydraulic shop down in Fort Worth called Kim's International. I guess I could ask them. I don't really have a slick way of putting a nice smooth 90 degree bend in a 5/8" line anyway so I might need to call in the professionals.

Re: The Hillbilly Deluxe dually build
 

I think I'm gonna pop rivet the fuel filler to the bedside. I'm shooting for the finished product to be smooth and not something I'll snag on when working beside the truck with tie down straps or fuel up or whatever.

http://i276.photobucket.com/albums/k...d7ca9cd5d6.jpg

Re: The Hillbilly Deluxe dually build
 

Oh crap, I just noticed there is a script oval visible on that fuel pocket. Any chance you can do a little sanding/filling on that? ;) Looking good, glad the weather is tolerable enough for you to do some tinkering. You know some pan head or dome head allen bolts in stainless would look nice around there. :D

Re: The Hillbilly Deluxe dually build
 

Looks awesome, going to leave the Ford logo? I agree with the stainless bolt idea. Would look nice.

Re: The Hillbilly Deluxe dually build
 

Sounds like two guys trying to politely say "rivets will look cheesy. Go with screws". Am I right ? I want honest opinions.

Re: The Hillbilly Deluxe dually build
 

At least pop rivets won't let loose. And will be less of a hassle too. Stainless steel screws will look nice though.

Re: The Hillbilly Deluxe dually build
 

You could also put a 3/4" inch stitch weld on each corner. Your rivets won't come loose that way! Good lookin' work!

Re: The Hillbilly Deluxe dually build
 

I just don't think the rivets would hold up over time.

Re: The Hillbilly Deluxe dually build
 

^^ x2.

Re: The Hillbilly Deluxe dually build
 

I was surprised to find these are fiberglass pieces. Judging by the ebay pictures, I figured they'd be steel. I have to use screws or rivets or duct tape or bubble gum.

I appreciate the opinions fellas. I'm off to McMaster Carr to find some nice stuff. I can't buy it local as cheap as I can mail order bulk stuff from them. And, I end up with a lot of leftovers for my bolt bins.

Re: The Hillbilly Deluxe dually build
 

Stainless steel button head screws, Stainless lock nuts, and Stainless washers ordered from McMaster Carr. I got 100 of each for about what I'd have paid for 10 each at my local place.

These are the screws I got. Built in flange washer to keep from digging into the fiberglass bezel.

http://i276.photobucket.com/albums/k...3c788ef4f4.jpg

Here is where all of my fuel filler parts stand. Been waiting for a long time for UPS to get it delivered.

http://i276.photobucket.com/albums/k...32409e8b81.jpg

Re: The Hillbilly Deluxe dually build
 

I like the screws. Don't forget the Anti-sieze! IDK how many hundred of those fuel cups I've riveted on, I worked for Knapheide building industrial trucks 1991-1994.

Re: The Hillbilly Deluxe dually build
 

I'm researching now about bonding straps for the filler neck. I seem to remember that when the filler tube is isolated from body ground like it is with this fiberglass bezel, a bonding strap is required.

Any input ?

Re: The Hillbilly Deluxe dually build
 

I would do it. The stock filler neck on my 86 has a ground strap to the bed, since the filler cup is plastic.

Re: The Hillbilly Deluxe dually build
 

on my '98 it had one from the factory since the bezel was plastic that mounted the neck to the bed side. Required or not, it makes good sense to put on. A few dollars today vs, huge dollars later if something were to happen. Accidents do happen...

I would put one on.

Re: The Hillbilly Deluxe dually build
 

Honestly, I think rivets will work just fine, just about every service bed I've seen has that pocket held in with rivets. I just didn't think that the rivet idea went with your level of attention to detail. You wet-sanded wheels for how long? Had how many fasteners coated? ;)

Re: The Hillbilly Deluxe dually build
 

Point well taken. No reason to cut corners now. I haven't so far. I wanted this truck for 20 years and now that I have it, I'm not gonna sell it, might as well go all the way on every step. Nice stainless hardware is on the way.

By the way, thank you for the advice via PM on the K2500. I wound up not buying the truck. I'm playing the silent game now to see if he lowers his price to a level I'm more comfortable with. The engine is pretty tired and I'm wanting the price to reflect that more.

Re: The Hillbilly Deluxe dually build
 

I'm going to agree on the screws. i don't like rivets. They just look to quick n' easy. being a bit of a masochist, i like to use countersunk hardware when it is reasonable. i just ordered 8) 1/2"x 4 1/2" stainless countersunk allen head bolts today at the tune of 7 bucks a shot for my rear bumper. silliness. i also prefer flange head bolts for most stuff so i end up ordering them a lot. i like to have a box of 3/8"-16 black oxide flange heads around for diff covers. new bolts always make a diff cover look better.

We have a pretty darn good fastener joint that comes to the shop twice a week. they can order most anything i can dream up, but if they dont have it, Mcmaster always seems to. that catalog really gets my wheels turning...

Re: The Hillbilly Deluxe dually build
 

I forget that McMaster-Carr exists...I grew up with Fastenal & a few years ago was introduced to Tacoma Screw.

Kevin, I was a starting to wonder about that K2500. Sounds like you are on the right track, if you looked at it and it's tired then the owner should come down to something reasonable.

Re: The Hillbilly Deluxe dually build
 

Tacoma Screw looks like a sweet place to hunt down some hardware and other fun stuff. We have a Fastenal local to me but they went ahead and made me mad. now they can suffer the nearly non existent loss of my business. I really wanted to spend my money there and they were about the worst CS ever. Sad too. The previous manager was amazing and would bend over backwards to help you.

Re: The Hillbilly Deluxe dually build
 

I forget that McMaster-Carr exists, too. I just went thru there website. They have a lot of hard to find stuff.
I am so glad we all agreed on the screws.

Re: The Hillbilly Deluxe dually build
 

Sometimes y'all just have to offer less than subtle hints to help me fine tune my tastes.

Re: The Hillbilly Deluxe dually build
 

Our Fastnal is pretty good. I have walked out of there for free a few times when I was just looking for one bolt or nut.

Re: The Hillbilly Deluxe dually build
 

I'd screw/solder a standard ground strap to the filler neck and then sand off the paint on the back of one of those screws and screw it on. Alternatively, you could drill/tap a nearby crossmember for easy access, and sand/grease a nice bare spot. Knowing you, I'm sure you've already got hella bed/chassis grounds.

Re: The Hillbilly Deluxe dually build
 

A bit of a lame weekend update. No real work done though.

After literally 11 days of being below the radar, my UPS finally showed up with my gas filler stuff.

http://i276.photobucket.com/albums/k...f2e0d85e3b.jpg

http://i276.photobucket.com/albums/k...370cfb6196.jpg

My stainless hardware is due from McMaster Carr Monday. Between the hardware and this box of stuff, I think I have what I need to get the fuel system finished up.

While I've been waiting, I did a little work on my daily driver Honda. I needed new tires so I got a set of steelie wheels off Craigslist and powder'd them at the same time.

http://i276.photobucket.com/albums/k...4cf09c18c9.jpg

Tomorrow is work day so I'll be at the fire station. But, Monday its due to be temperatures in the 60s so I should have good progress made.

Re: The Hillbilly Deluxe dually build
 

I got lucky and scored a vacation spot today, so no fire station for me.

I worked some more on the fuel filler today. The piece of exhaust tubing I bought from a Summit worked out very well.

It was bare metal so I coated it in Super Durable Wet Black. No real reason, I just still had some loaded into the gun from powdercoating wheels yesterday.


http://i276.photobucket.com/albums/k...b50e8d4f59.jpg


http://i276.photobucket.com/albums/k...af011c28e1.jpg


I'm hoping I've built enough slope into the system for quick fueling.

http://i276.photobucket.com/albums/k...9d4f9e572d.jpg


http://i276.photobucket.com/albums/k...756960cd69.jpg


http://i276.photobucket.com/albums/k...b22e2a4725.jpg


http://i276.photobucket.com/albums/k...1ce55b72bc.jpg


http://i276.photobucket.com/albums/k...4448e8456c.jpg


I'm still waiting on my McMaster Carr order to arrive tomorrow with my stainless steel hardware.

What say y'all, do I have enough slope in the system ?

Re: The Hillbilly Deluxe dually build
 

i think so. my jeep enters the tank basically flat and it fuels fast. it has a huge filler, but at the tank its only ~2" i think the issue is no tight bends or spots for it to back up. looks nice and smooth to me.

Re: The Hillbilly Deluxe dually build
 

Like Ryanroo said, I think that the key is no bottlenecks and some slope in the fill tube. Looks really nice!

Re: The Hillbilly Deluxe dually build
 

Looks good to me!

Re: The Hillbilly Deluxe dually build
 

Rather than fool with getting fancy on the vent hose, I just ran up to the parts store and bought 4 feet of 5/8" fuel vent hose. Four bucks. Installed quick and easy.

I'm happy to report that it took five gallons of gas out of my gas can as quickly as the can would pour it out. Looks like problem solved.

Tomorrow starts front suspension, brakes, lowering, and front wheels. Should be fun.

For the remainder of today, I have to reorganize my shop a bit. I was seating some tires on the wheels with ether and a torch yesterday and overdid it a little bit. The concussion knocked a shelf off the wall and dumped a bunch of stuff. It wasn't a real massive explosion, but kind of a shock wave. I had the wheel and tire elevated up on a 5 gallon bucket, and it split the bucket in half.